C-frame structural module

ABSTRACT

A C-shaped core module constructed of metal skeletal elements, a number of which are embedded in rigid self-skinned polyurethane foam, assembled so that the polyurethane foam material provides both strength and a decorative finish, the module being adapted to accomodate and support sinks, shelves, cupboards, storage cabinets, drawers, hangers, electrical and lighting fixtures and plumbing arrangements useful in hospital pharmaceutical units, laboratories, and various mobile assemblies such as marketing displays.

United States Patent 1191 Rudat et al.

C-FRAME STRUCTURAL MODULE Inventors: Emil A. Rudat, North Reading;

Edwin J. Medler, Millbury, both of Mass.

Innovations Incorporated, Worcester, Mass.

Filed: Sept. 1, 1972 Appl. No.: 285,940

Assignee:

us. on 108/108, 108/152, 312/107 Int. Cl A47b 9/00 Field of Search.....248/127; 108/108; 312/107,

, References Cited UNITED STATES PATENTS Cousino 52/710 Gingher et a1Strom .1 312/111 Primary Examiner-Marion Parsons, Jr. Attorney, Agent,or Firm-Thomas N. Tarrant 1 1 ABSTRACT A C-shaped core moduleconstructed of metal skeletal elements, a number of which are embeddedin rigid self-skinned polyurethane foam, assembled so that thepolyurethane foam material provides both strength and a decorativefinish, the module being adapted to accomodate and support sinks,shelves, cupboards, storage cabinets, drawers, hangers, electrical andlighting fixtures and plumbing arrangements useful in hospitalpharmaceutical units, laboratories, and various mobile assemblies suchas marketing displays.

10 Claims, 4 Drawing Figures 1 C-FRAME STRUCTURAL MODULE BACKGROUND OFTHE INVENTION 1. Field of the Invention The present invention relates tomodular structural assemblies for supporting an assortment of usefulsubassemblies such as drawers, cupboard shelves, sinks, range top units,etc. and in particular to such an assembly constructed in a C-frame of aunique combination of foam plastic and structural metal elements.

2. Description of the Prior Art Pharmaceutical units and laboratories inhospitals have been going through a seige of growth and change agoniesin recent years which have proved both costly and annoying due to theinterference with normal operation during changes. One particular newdemand is in the mounting number of .special Care facilities. Thesefacilities are in a constant emergency status and have a need forlaboratory and pharmaceutical facilities right at hand, the delay inusing central facilities frequently being excessive.

Construction of laboratory and pharmaceutical installations has usuallybeen by custom building. Available units are mostly restricted tolimited applications and are not readily convertable or movable forfacilitating change. The more common steel assemblies are readilydamaged in moving and lack uniformity of strength to accomodate supportof a wide variety of appended units from a similar wide variety ofsupporting points.

SUMMARY OF THE INVENTION Now, in accordance with the present invention aC- frame structural unit is provided, highly resistant to damage andwith provisions for appending heavy subassemblies from most desirablepoints. A back member and identical top and bottom members are made ofrigid self-skinned foam plastic with structural metal members embedded.Two L-shaped structural metal side assemblies secure the back, top andbottom members together. Structural metal channel members embedded inthe back member facilitate securing of various subassemblies andsubcomponents.

Thusfit is an object of the invention to novel core module for clinicalfacilities.

It is a further object of the invention to provide a novel integrationof foam plastic and structural steel to form core structures formiscellaneous facilities.

Further objects and features of the invention will beprovide a .comeapparent upon reading the following description together with thedrawing.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of aC-frame module according to the invention.

FIG. 2 is a partial side elevation in section taken along 2-2 of FIG. 1.

FIG. 3 is a partial front elevation in section taken along 3-3 of FIG.1.

FIG. 4 is a partial plan view of the module of FIG. I with dust coverremoved.

DESCRIPTION OF THE PREFERRED EMBODIMENT In the present invention, a freestanding general purpose supporting frame is made by molding top, bottomand back components and then assembling them togetherwith furtherstructural metal elements.

The depicted embodiment utilizes top and bottom molded components thatare identical for symmetry of form and economy of manufacture. Thus,referring to FIG. I, it will be seen top 11 is an inverted replica ofbottom 12. Top 11 and bottom 12 are molded hollow, but in FIG. I, dustcover 14 covers the hollow of top 11 and the hollow of bottom 12 facesdown. Back panel 15 is a flat molded panel depicted as molded in twoidentical pieces joined at junction 16. Back 15 can readily be molded inone piece, but the use of smaller molds facilitates manufacture andhandling. As can be seen in FIGS. 2 and 4, back panel 15 is only a smallpart of the thickness of back component 17 and in FIG. 1, side 18 ofback component 17 is covered by a decorative strip 20. Strip 20 issuitably a self-adhesive plastic laminate which is used on side 18 onlywhen it is exposed to view.

Back panel 15 is molded of a rigid self-skinned foam plastic withstructural metal channel members 21 and 22 molded into the panel.Members 21 and 22 are arranged in parallel spaced apart relationship sothat they will lie vertically in an installed module. Channel members 21and 22 are molded into the plastic so that the channel openings 24 and25 are flush with the front surface of panel 15. Channels 21 and 22 aredesigned to permit insertion of fasteners for securing various accessorycomponents to the module.

Polyurethanes are the most readily available plastics for self-skinnedfoam systems suitable for molding top 11, bottom 12 and back panel 15 inaccordancewith the invention. v

Self-skinned polyurethane foam systems are available in many varieties.They are provided with two reactive components that are mixed, placed ina mold and blown with a gas such as carbon dioxide, freon. varioushaloginated hydrocarbons, etc. The mold limits expansion so that themolded density is commonly about twice that of free rise and can be,varied widely by choice. The resulting molded product has a solid denseouter skin with the surface textureof the mold and has a graduallycoarsening cellular structure inwardly of the skin.

While a wide range of these foam materials would be suitable for thepresent module, one example that has been used is Stepanthane No. RM-4l,available from Stepan Chemical Company of Northfield, Illinois.Stepanthane RM-4l has been used in a density of approxi mately 20 poundsper cubic foot. Strength characteristics of the different materials areavailable from the suppliers and some systems require densities as highas 40 pounds per cubic foot for comparable strength.

The structural metal elements molded integrally with the plastic arepositioned in the mold at the time of molding. Most of the polyurethanefoam systems will form strong dense adherence to such inserted metalelements.

Now, referring to FIG. 2, back panel 15 is molded with a plurality ofspacers 27 underlying channel members 21 and 22. Through spacers 27,each of channels 21 and 22 are fastened to separate vertical standingstructural metal channel members 28 and 30. The configuration of channelmembers 28 and 30 is illustrated by top end view in FIG. 4 of member 30.Member 28 can be seen from the inside in FIG. 2.

Channel member 21 and 22 are secured to channel member 30 and 28respectively by means of fastenings 31. Fastenings 31 are suitably flatheaded machine screws passing through spacers 27 and screwed intothreaded inserts 34 in'channel members 21 and 22. ln some cases it hasbeen found preferable to reverse fastenings 31 using a truss head screwentering through channel members 21 and 22. Nuts and lockwashers wouldthen secure the screws through channel members 30 and 28. This latterarrangement leaves more clearancefor other fasteningsin channel members21 g and 22.

Two further channel members 35 and 36 are secured to channel members 30and 28 respectively so that they are vertically positioned, spaced inback of channel members 21 and 22. Channel members 28 and 30 containknock outs 37 facing the sides of the module to allow for entrance ofpipes and electrical wiring. Heavy flat metal pieces 38 are positionedexternally of panel members 28 and 30 to provide additional strength.These flat metal pieces 38 are shown in top view, FIG. 4. Knock outs 37are in members 38 as Well as members 28 and 30. Members 38, as depictedin FIG. 4, extend to cover the side edge of back panel and'toward theback of the module to cover the edge of a rear cover 62 which encloses aspace for plumbing and wiring. Flat metal members 38 are secured tochannel members 28 and 30 by spot welding or other fastening means. I

Bottom 12 contains channel members 40 and 41 molded integral with theplastic similar to channels 21 and 22. Channel members 40 and 41 extendfrom front to back of bottom 12 with their openings 42 and 44 openingdownwardly inside bottom 12. Fastened into channels 40 and 41 areseparate structural metal members 45 and 46 made of flat metal stripsbent into upwardly reversing bends at each end.

Members 45 and 46 are secured to channel members 40 and 41 byfastenings-at the reversing lips of the bent ends. Bottom 12 is moldedwith skirts 48 on both side and the front extending far enough toconceal structural members 45 and 46. Bottom 12 is secured to back 17 byfastenings 50 and 51 passing through structural members 45 and 46respectively, and secured by nuts in channel members 21 and 22respectively.

Bottom 12 is additionally secured to back component 17 by means'of twobottom channel members 52 and 53 which are bolted to members 45 and 46by fastenings 54 and 55 respectively'and to channel members 35 and 36 bytwo corner brackets 56 of which only the right one is illustrated inFIG. 2. While channel members 52 and 53 are depicted with their opensides facing down, it is frequently preferable to invert them to providea flat solid surface for resting on the floor. The choice is made on thebasis of whether further feet of some sort such as casters are to beadded and which way the particular feet are most easily attached.

Corner brackets 56 have horizontal bottom legs suitably screwed intothreaded fasteners 57 in channel members 52 and 53. The upward bendinglegs of corner brackets 56 are suitably fastened by similar threadedfasteners into channel members 35 and 36.

Top 11 has two metal members 58 and 59 which are identical to members 45and 46 in bottom 12 and are fastened to back components 17 by fasteners63 the same as 51 for bottom 12.

Skirts 60 for top 11 face upwardly and a dust cover 14 is secured to thetop of top 11 by sheet metal screws 61 which thread into members 58 and59. Dust cover 14 extends to the rear of topll to cover back component17. A back dust cover 62 suitably of .polyurethane is secured to theback of the module by means of sheet metal screws 64 which thread intovertical members 30, 28, 35 and 36.

The modules are readily installed side by side in a plurality of unitsby bolting adjoining units together through bolt holes 65 shown in FIG.2. The bottoms of adjoining units may also be secured together bybridging straps secured to channel members 52 and 53. These bridgingstraps then become suitable for accepting leveling feet or rollers tofacilitate moving.

While it has been found possible to support 400 lbs. from the outer edgeof top 11, it is contemplated that support for accessory components willbe provided entirely from channel members 21 and 22. It is alsocontemplated that lighting units may be installed in top 11.

While the invention has been described in relation to a specificembodiment, various arrangements in the C- form of similar combinationsof self-skinned foam plastics with structural metal reinforcement arecontemplated as within the scope of the invention and in accordance withthe following claims.

I claim:

1. A structural module for supporting shelves, cupboards, sinks and thelike comprising:

a. Vertical supports comprising two spaced structural metal supportmembers;

b. Lateral supports consisting of a bottom panel, a back panel and a toppanel made of self-skinned rigid foam plastic;

c. Connecting elements comprising longitudinal channel metal integrallymolded into each of said bottom panel, back panel and top panelproximate each side thereof, and

d. Fastening means for connecting said connecting elements to saidvertical supports whereby said bottom panel, said back panel and saidtop panel are securely fastened together into a rigid selfsupportingstructure having thegeneral shape in side aspect of a C."

2. A structural module according to claim 11 wherein said connectingelements in said back panel are channel members arranged vertically withthe channel opening facing the front of the module and adapted toreceive fastenings for securing various accessory components to saidmodule.

3. A structural module according to claim 11 wherein said metal supportmembers are vertical channel members having their channel openingsfacing each other, and said vertical supports each further comprise avertical flat member and a horizontal channel member secured to eachvertical channel member so that each said vertical channel member issecured together in an L-shape with a respective flat member andhorizontal channel member and the vertical supports are held in spacedapart relationship by said bottom panel, said back panel and said toppanel.

4. A structural module according to claim 11 wherein said top panel andsaid bottom panel are identical moldings.

5. A modular frame assembly for supporting shelves, cabinets, sinks andvarious miscellaneous facilities and accessories comprising:

a. Top, back and bottom assemblies of molded selfskinned rigid foamplastic with integral metal support members; and,

b. Vertical structural metal members secured to said integral metalsupport members holding said top, back and bottom assemblies together ina substantially C-shaped configuration.

6. A modular frame assembly according to claim 5 in which said metalsupport members integral in said back assembly are two vertical spacedapart channel members adapted to receive fasteners for supportingaccessory units.

7. A modular frame assembly according to claim 5 in which said verticalstructural metal members comprise two rear channel members, one on eachside of said module and two flat stiffening members, one secured to eachof said rear channel members and adapted for fastening a plurality ofmodules in side-by-side relationskirts molded into said top and bottomassemblies.

1. A structural module for supporting shelves, cupboards, sinks and thelike comprising: a. Vertical supports comprising two spaced structuralmetal support members; b. Lateral supports consisting of a bottom panel,a back panel and a top panel made of self-skinned rigid foam plastic; c.Connecting elements comprising longitudinal channel metal integrallymolded into each of said bottom panel, back panel and top panelproximate each side thereof, and d. Fastening means for connecting saidconnecting elements to said vertical supports whereby said bottom panel,said back panel and said top panel are securely fastened together into arigid self-supporting structure having the general shape in side aspectof a ''''C.''''
 2. A structural module according to claim 11 whereinsaid connecting elements in said back panel are channel members arrangedvertically with the channel opening facing the front of the module andadapted to receive fastenings for securing various accessory componentsto said module.
 3. A structural module according to claim 11 whereinsaid metal support members are vertical channel members having theirchannel openings facing each other, and said vertical supports eachfurther comprise a vertical flat member and a horizontal channel membersecured to each vertical channel member so that each said verticalchannel member is secured together in an L-shape with a respective flatmember and horizontal channel member and the vertical supports are heldin spaced apart relationship by said bottom panel, said back panel andsaid top panel.
 4. A structural module according to claim 11 whereinsaid top panel and said bottom panel are identical moldings.
 5. Amodular frame assembly for supporting shelves, cabinets, sinks andvarious miscellaneous facilities and accessories comprising: a. Top,back and bottom assemblies of molded self-skinned rigid foam plasticwith integral metal support members; and, b. Vertical structural metalmembers secured to said integral metal support members holding said top,back and bottom assemblies together in a substantially C-shapedconfiguration.
 6. A modular frame assembly according to claim 5 in whichsaid metal support members integral in said back assembly are twovertical spaced apart channel members adapted to receive fasteners forsupporting accessory units.
 7. A modular frame assembly according toclaim 5 in which said vertical structural metal members comprise tworear channel members, one on each side of said module and two flatstiffening members, one secured to each of said rear channel members andadapted for fastening a plurality of modules in side-by-siderelationship.
 8. A modular frame assembly according to claim 5 whereinsaid molded foam plastic is a rigid self-skinned polyurethane foamhaving an average density in the range of 20 to 40 pounds per cubicfoot.
 9. A modular frame assembly according to claim 8 wherein saidmetal support members and said structural metal members are steel.
 10. Amodular frame assembly according to claim 5 wherein the metal supportmembers for said top and bottom assemblies are concealed from view byplastic skirts molded into said top and bottom assemblies.